System for reducing head space in a pressure cyclone

ABSTRACT

A pressure cyclone is disclosed having a concave top head, wherein the concave top head has a substantially flat roof disposed in the interior of the cyclone vessel. An inlet is tangentially-coupled to the vessel and has an inlet nozzle disposed therein and configured to smoothly transition into the cyclone vessel to create a vortex that separates solid particulates from an incoming particulate-fluid suspension. In particular, the one surface of the inlet nozzle is tangent to the inner surface of cyclone vessel and another surface of the inlet nozzle is parallel and continuous with the substantially flat roof. An inlet casing is disposed around a length of the inlet nozzle and configured to transition from a circular casing to an elliptical casing along the length of the inlet nozzle, and couple to the vessel with the elliptical casing.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of co-pending U.S. patent applicationSer. No. 12/773,206, filed on May 4, 2010, which is incorporated byreference herein.

BACKGROUND OF THE INVENTION

1. Field of the Invention

Embodiments of the present invention generally relate to cyclonicseparation units. More particularly, embodiments of the presentinvention relate to high-pressure cyclones.

2. Description of the Related Art

Cyclonic separation involves separating a mixture of two or more phases,for example, fluid-particulate suspensions wherein one or more solidparticulates are suspended in a carrier fluid, under a centrifugal forcegenerated by centripetal motion. A cyclone separator is the mechanicaldevice typically used to carry out cyclonic separation processes. Innormal cyclone separator operation, a particulate suspension isintroduced into the top of the cyclone separator via a tangential inletwhere the solid particles tend to collect on the inner surface of theseparator and its fluidic counterpart is entrained into a vortex. Thesolid particles gradually fall to the bottom of the separator vessel forfurther processing, while the fluidic counterpart is eventually drawnthrough a centrally-located output tube. Uses of cyclonic separationmethods can include unit operations to purify a phase, to concentrate aphase, to terminate chemical and physical interactions between mixedphases, or combinations thereof.

In applications exhibiting high and ultrahigh pressures, cyclonicseparation operations are typically undertaken by a pressure cycloneseparator. Pressure cyclones generally consist of a compression-proofvessel that is geometrically and structurally designed to resistelevated pressures and temperatures. However, it is nonetheless notunheard of to employ pressure cyclones in low-pressure environments. Inpractice, a pressure cyclone can be manufactured to almost any size ordimension to fit any particular separation application.

At least one high-pressure application that is appropriate for apressure cyclone includes hydrocarbon gasification processes, wherecarbonaceous materials, such as coal, petroleum, crude oil, tars,biofuel, or biomass, are converted into a “syngas,” such as carbonmonoxide and hydrogen. Depending on the hydrocarbon used and theconversion process employed, pressures in a hydrocarbon gasificationprocess can range from about 50 psi to about 1,000 psi, and even up toultrahigh pressures of about 7,000 psi. Because of thesepotentially-extreme conditions, the structural design of pressurecyclones is a vital concern if it is to endure a long production life.

The top head and tangential inlet of the pressure cyclone are keycomponents in improving the overall efficiency of high-pressure cyclonicseparation processes. In prior applications, the top head has beendesigned as a flat surface near the inlet entrance, thereby creatingjoints and edges reflecting a significant propensity to fail underelevated pressures and temperatures. Prior applications have implementeda semi-spherical, convex top head to take advantage of the structuralintegrity of an arced surface in order to withstand the elevatedpressures. However, the convex top head design essentially creates avoid area between the tangential inlet and the top head where the vortexcan be significantly disturbed, thereby resulting in a significantreduction in efficiency of the separation process.

Likewise, the casing surrounding the tangential inlet has often beendesigned with square or rectangular features that also have a tendencyto fail or crack under extreme conditions. In applications using acontinuously-circular inlet casing, the inlet nozzle is oftentimesrequired to be shifted into direct or semi-direct alignment with acentrally-located vortex output tube, thereby injecting particulatematter directly at the output tube which prematurely erodes its surfaceand disturbs the vortex. To remedy this, some designs have implemented abend in the output tube, thereby placing it off-center from the vortexand effectively reducing the efficiency of the process.

What is needed, therefore, is an improved top head design and tangentialinlet for pressure cyclones that can withstand elevated pressures andmaintain or increase process efficiency.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the recited features of the present invention can be understoodin detail, a more particular description of the invention may be had byreference to embodiments, some of which are illustrated in the appendeddrawings. It is to be noted, however, that the appended drawingsillustrate only typical embodiments of this invention and are thereforenot to be considered limiting of its scope, for the invention may admitto other equally effective embodiments.

FIG. 1 depicts a side view of an exemplary cyclone, according to one ormore embodiments of the disclosure.

FIG. 2 depicts a top view of the exemplary cyclone of FIG. 1, accordingto one or more embodiments of the disclosure.

FIG. 3 depicts a portion of a top head as shown in FIG. 1, according toone or more embodiments of the disclosure.

FIG. 4 depicts a side view of the cyclone inlet, according to one ormore embodiments of the disclosure.

FIG. 5 depicts an end view of the cyclone inlet of FIG. 4 taken alongthe line 5-5 indicated in FIG. 4, according to one or more embodimentsof the disclosure.

FIG. 6 depicts an opposing end view (with respect to the end view shownin FIG. 5) of the cyclone inlet of FIG. 4 taken along the line 6-6indicated in FIG. 4, according to one or more embodiments of thedisclosure.

FIG. 7 depicts a portion of the top head with an exemplary rain shielddisposed thereon, according to one or more embodiments of thedisclosure.

FIG. 8 depicts a magnification of the cap portions indicated in FIG. 7.

DETAILED DESCRIPTION

A detailed description will now be provided. Each of the appended claimsdefines a separate invention, which for infringement purposes isrecognized as including equivalents to the various elements orlimitations specified in the claims. Depending on the context, allreferences below to the “invention” may in some cases refer to certainspecific embodiments only. In other cases it will be recognized thatreferences to the “invention” will refer to subject matter recited inone or more, but not necessarily all, of the claims. Each of theinventions will now be described in greater detail below, includingspecific embodiments, versions and examples, but the inventions are notlimited to these embodiments, versions or examples, which are includedto enable a person having ordinary skill in the art to make and use theinventions, when the information in this patent is combined withpublicly available information and technology.

FIGS. 1 and 2 depict an exemplary cyclone 100, according to one or moreembodiments of the present disclosure. FIG. 1 depicts a side view of theexemplary cyclone 100, while FIG. 2 depicts an end view of the same. Inan exemplary embodiment, the cyclone 100 can be configured as a pressurecyclone as used in high-pressure cyclonic separation applications. In atleast one embodiment, one high-pressure cyclonic separation applicationcan include hydrocarbon gasification processing. However, the exemplarycyclone 100 can be equally effective in low-pressure applications, suchas fluid catalytic cracking units where catalyst particles arecyclonically-separated from a hydrocarbon vapor suspension.

As illustrated, the cyclone 100 can include a cyclone vessel 102generally defining a cylindrical structure having an inlet 104 and anoutlet 106, where the outlet 106 includes an outlet tube 105 configuredto sealingly penetrate a top head 107. In at least one embodiment, thecyclone vessel 102 can be configured as a pressure-vessel enabled towithstand elevated pressures and temperatures in cyclonic separationprocesses. The cyclone vessel 102 can include a vessel casing 108, anerosion resistant layer 110, and an insulating layer 112 interposedbetween the vessel casing 108 and the erosion resistant layer 110. Inone or more embodiments, the vessel casing 108 can generally define theoutside surface of the cyclone vessel 102, while the erosion resistantlayer 110 generally defines an inner cylindrical surface 126.

The vessel casing 108 can be made of, for example, carbon steel, such asa low-alloy steel, but can also be manufactured of other materialshaving similar strength characteristics as carbon steel. The erosionresistant layer 110 can include a dense layer refractory material,either a pressed or monolithic refractory, configured to protect theadjacent insulating layer 112 and provide a surface 126 where solidparticulate can collect, as will be described below. In at least oneembodiment, the erosion resistant layer 110 can be made of RESCO® RS-88VC refractory material (Resco Products, Inc.), and can be installed byvibracasting techniques.

The insulating layer 112 can serve as a back-up refractory layer, butmore importantly can provide an insulating material for the cyclonevessel 102. In at least one embodiment, the insulating layer 112 caninclude a thermal ceramic, such as KAOLITE® 2300 LI thermal ceramic(Thermal Ceramics, Inc.), and can be installed by casting techniques.The insulating layer 112 can be configured to withstand elevatedtemperatures of around 1800° F.

As best illustrated in FIG. 2, the inlet 104 can betangentially-disposed on the cyclone vessel 102 and include an inletcasing 116, an inlet erosion resistant layer 118, and an inletinsulating layer 120 interposed between the inlet casing 116 and theinlet erosion resistant layer 118. As will be described in more detailbelow, the inlet casing 116 can be substantially cylindrical along itslength, but gradually tapering or transitioning along its length into anelliptical or oval-like conduit as it eventually intersects the vesselcasing 108. In at least one embodiment, the inlet 104 can be welded tothe cyclone vessel 102 to ensure a pressure-tight interconnection. Inother exemplary embodiments, the inlet 104 can be mechanically coupledor otherwise attached to the cyclone vessel 102, while maintaining apressure-resistant interconnection.

In an exemplary embodiment, the inlet casing 116 can be made of carbonsteel, such as low-alloy steel. Similar to the erosion resistant layer110, the inlet erosion resistant layer 118 can include a dense layerrefractory material, such as RESCO® RS-88VC refractory material, and canbe installed by vibracasting techniques, as known in the art. The inletinsulating layer 120 can serve as a back-up refractory layer to theinlet erosion resistant layer 118 and also provide insulation along thelength of the inlet 104. In at least one embodiment, the inletinsulating layer 120 can include a thermal ceramic, such as KAOLITE®2500 LI (Thermal Ceramics, Inc.), and can be installed by gunningtechniques, as known in the art.

An inlet nozzle 122 can be defined in and generally centered along thelength of the inlet 104 toward the cyclone vessel 102. In at least oneembodiment, the inlet nozzle 122 can be rectangular in shape, having afirst surface 124 substantially tangent to and continuous with the innercylindrical surface 126 of the cyclone vessel 102. Moreover, the inletnozzle 122 can have a second surface 128 substantially parallel andcontinuous with a cyclone roof 130 of the cyclone vessel 102, whereinthe cyclone roof 130 forms part of the top head 107. Thus, the firstsurface 124 and the second surface 128 can each provide a smoothtransition for any incoming fluid-particulate suspension from the inletnozzle 122 to the inner cylindrical surface 126 and cyclone roof 130,respectively. As can be appreciated, other exemplary embodiments caninclude a substantially square-shaped inlet nozzle 122 having similarfirst and second surfaces 124,128, without departing from the scope ofthe disclosure.

In exemplary operation, a fluid-particulate suspension containing one ormore solid particulates suspended in a fluid can enter the cyclonevessel 102 tangentially through the inlet nozzle 122 and swirlcircumferentially against the inner cylindrical surface 126, therebycreating a centrally-located vortex of reduced solids content. In atleast one embodiment, the fluid-particulate suspension can be introducedto the cyclone vessel 102 at elevated temperatures and pressures. Forexample, in one or more embodiments the incident pressures Can rangefrom a lower end of about zero psi, about 100 psi, about 200 psi, about300 psi or about 400 psi to an upper end of about 500 psi, about 600psi, about 700 psi, about 800 psi, about 900 psi or about 1000 psi.Further, the incident pressures can range from about 500 psi to about900 psi, or from about 600 psi to about 800 psi, from about 700 psi toabout 800 psi. The incident temperatures can range from a low end ofabout 100° F., about 200° F., about 300° F., about 400° F., about 500°F., about 600° F., about 700° F., about 800° F., about 900° F. or about1000° F. to and upper end of about 1100° F., about 1200° F., about 1300°F., about 1400° F., about 1500° F., about 1600° F., about 1700° F.,about 1800° F., about 1900° F. or about 2000° F. Further, that incidenttemperature can range from about 1500° F. to about 2000° F., about 1600°F. to about 1900° F., about 1700° F. to about 1800° F. or from about1550° F. to about 1850° F. In other exemplary embodiments, the pressurewithin the cyclone vessel can reach ultrahigh pressures of greater than1000 psi, such as 2000 psi, 3000 psi, 4000 psi, 5000 psi, 6000 psi andeven up to about 7000 psi or more.

Once injected into the cyclone vessel 102, the suspended solidparticulates can be immediately driven outward toward the innercylindrical surface 126 by centrifugal forces. The disentrainedparticulates rapidly concentrate at the inner cylindrical surface 126and gradually pass downward through the cyclone vessel 102 fordownstream processing. At the same time, the separated fluid phase ofdecreasing particulate loading can eventually form a centrally-locatedvortex. From the vortex, a solids-lean fluid, such as gas or fuel, canexit via the outlet tube 105 to the outlet 106.

Referring now to FIG. 3, illustrated is a portion of the top head 107,as indicated in FIG. 1. According to one or more embodiments of thepresent disclosure, the top head 107 can be circumferentially-disposedaround and sealingly engaged with a portion of the outlet tube 105. Inat least one embodiment, the top head 107 can include the cyclone roof130, as discussed above, a concave casing 302, and a roof insulationlayer 304 interposed therebetween. The cyclone roof 130 can include adense layer refractory, such as RESCO® RS-88VC, and be configured toprevent erosion of the roof insulation layer 304. As described above,the cyclone roof 130 can also be configured to provide a flat surfacesubstantially parallel and continuous with the second surface 128 of theinlet nozzle 122 (see FIGS. 1 and 2).

In one or more embodiments, the cyclone roof 130 can include a series ofpie-shaped refractory bricks, circumferentially-surrounding the outlettube 105 and interconnected with each other through, for example, atongue-and-groove or keyed joint. In at least one embodiment, eachpie-shaped refractory brick of the cyclone roof 130 may be coupled toand supported within the cyclone vessel 102 by one or more T-studs 306a,b,c cast directly into the bricks of the cyclone roof 130 and attachedor otherwise coupled to the concave casing 302. In other embodiments, ashoulder 308 of the erosion resistant layer 110 and a ring 310, coupledor otherwise attached to the outlet tube 105, can provide furthersupport for the cyclone roof 130 refractory bricks. In at least oneembodiment, the ring 310 can be disposed circumferentially about theoutlet tube 105 and made of an alloy, such as HAYNES® HR-120® (HaynesInternational).

The roof insulation layer 304 can serve as a back-up refractory layer tothe cyclone roof 130 and further provide an insulating material. In atleast one embodiment, the roof insulating layer 304 can include athermal ceramic, such as KAOLITE® 2300 LI thermal ceramic, and can beinstalled by casting techniques.

In illustrative embodiments, the concave casing 302 can beinwardly-concave toward the interior of the cyclone vessel 102 butconvex to the pressure, as typified by the Boiler and Pressure VesselCode provided by ASME. The concave casing 302 can be welded, orotherwise attached by mechanical means, to the casing 108 of the cyclonevessel 102. As can be appreciated, employing the inwardly-concave casing302 to the top head 107 takes advantage of the resilient structuralproperties of an arced member for use in high-pressure applications,whereas similarly-situated non-arced members (e.g., a flat member) wouldbe unable to withstand the elevated pressures and would ultimately fail.Moreover, the concave casing 302 of the top head 107 can eliminateunneeded and process-inefficient voids created between the inlet 104 andthe cyclone roof 130. Eliminating the void between the inlet 104 and thecyclone roof 130 can not only improve overall process efficiency, butcan also result in a substantial cost savings in materials needed tofill or seal the void.

Referring now to FIGS. 4-6, depicted is the inlet 104 of the cyclonevessel 102 and an exemplary structural transformation of the inletcasing 116 along the length of the inlet 104. As illustrated, the inlet104 can include a longitudinal axis 402 along which the inlet nozzle 122concentrically extends into the cyclone vessel 102. In at least oneembodiment, the inlet nozzle 122 can be rectangular, but otherembodiments can include a square-shaped inlet nozzle 122 or otherpolygonal shapes without departing from the scope of the disclosure. Theinlet nozzle 122 can at least be configured to direct any incomingfluid-particulate suspension away from and/or around the outlet tube105, thereby decreasing the potential of premature erosion on thesurface of the outlet tube 105.

Furthermore, as described above with reference to FIGS. 1 and 2, theinlet nozzle 122 can include a first surface 124 and a second surface128, wherein each surface 124, 128 provides a smooth transition from theinlet nozzle 122 to the inner cylindrical surface 126 and cyclone roof130, respectively. In addition, the inlet nozzle 122 can include a thirdsurface 404 and a fourth surface 406, where the third surface 404 facesthe first surface 124 and the fourth surface 406 faces the secondsurface 128. In at least one embodiment, the third surface 404 can beconfigured to help direct the incoming stream of fluid-particulatesuspension away from and/or around the centrally-located outlet tube105. In one or more embodiments, the shape of the inlet nozzle 122defined by its surfaces 124, 128, 404, 406, whether it be rectangular,square, or any other shape, can remain substantially constant along thelength of longitudinal axis 402. In at least one embodiment, surfaces124, 128, 404, 406 may merge together to form a substantially circularcross-sectional shape.

FIG. 5 depicts a view from a first end of the inlet 104 distal to thecyclone vessel 102, taken along line 5-5 as indicated in FIG. 4, andshows the inlet nozzle 122 encased by the inlet erosion resistant layer118, the inlet insulating layer 120, and the inlet casing 116. FIG. 6depicts a view from a second end of the inlet 104 proximal the cyclonevessel 102, taken along line 6-6 as indicated in FIG. 4, where the inlet104 can be coupled to or otherwise attached to the cyclone vessel 102.In one or more embodiments, the inlet casing 116 can be generallycircular in cross-section (FIG. 5) distal to the cyclone vessel 102, butmay gradually transform in shape along the length of the longitudinalaxis 402 and eventually transition into a generally elliptical, oroval-like cross-section (FIG. 6) at or near the cyclone vessel 102. Thetransformation of the inlet casing 116 from a generally circular shapeinto a generally elliptical shape along the longitudinal axis 402 canprovide a tapered connection point configured to smoothly transitioninto the outer surface of the cyclone vessel 102.

As can be appreciated, the tapering transition of the inlet casing 116can prove advantageous over applications employing auniformly-cylindrical inlet casing which is difficult to smoothlytransition to the cyclone vessel 102 for attachment without shifting thelongitudinal axis 402 into the path of the downwardly-extending outlettube 105. Such a shift in the longitudinal axis 402 would result in thedirect impact of incoming particulates on the outlet tube 105, therebyprematurely eroding its surface, or would necessitate a repositioning ofthe outlet tube 105 within the cyclone vessel 102 to avoid directparticulate contact. Repositioning the centrally-located outlet tube105, however, can have adverse effects on vortex efficiency and overallprocess efficiency.

Referring now to FIGS. 7 and 8, depicted is an exemplary rain shield 700that can be circumferentially-disposed around the outlet 106 of thecyclone 100 (FIG. 1) to prevent rainwater accumulation on the exteriorof the top head 107 where the concave casing 302 is located. Asillustrated in FIG. 7, the rain shield 700 can include a series of capportions 702 horizontally-disposed from the outlet 106 at varying pointsalong the length of the outlet 102. Although a certain number of capportions 702 are illustrated herein, it is understood that such ismerely by way of example, and not intended to limit the scope of thesubsequently presented claims. Indeed, a greater or lesser number of capportions 702 can be implemented to fit a particular application, withoutdeparting from the scope of the disclosure.

In one or more embodiments, each cap portion 702 can be configured toextend at least partially around the outlet 106 at a given point alongits length with respect to the outlet 106. After extending partiallyaround the outlet 106, the cap portion 702 can there be coupled orotherwise attached to another cap portion 702, and so on until the capportions 702 extend completely around the outlet 106 at the given point.The same process can be undertaken at each elevation, as shown in FIG.7. In at least one embodiment, the cap portion 702 can include twohalf-circle cap portions 702 that interconnect halfway around the outlet106, thereby providing a full circular cap portion 702 at a given point.In another exemplary embodiment, the cap portion 702 can include asingle circular length configured to extend completely around thecircumference of the outlet 106.

The cap portions 702 can all generally be supported by a series ofsupport plates 704 (only one shown), each support plate 704 beingcircumferentially-disposed around the exterior of the outlet 106.Although only one cap portion 702 at a given point may actually becoupled to a support plate 704, each cap portion 702 can be supportedthereby through the internal support structure between each cap portion702, as will be described below. In at least one embodiment, there canbe about eight support plate(s) 704 coupled or otherwise attached to theexterior of the outlet 106. In one or more embodiments, the supportplate(s) 704 can be welded to the exterior of the outlet 106. In otherexemplary embodiments, the support plate(s) 704 can be mechanically orotherwise attached to the exterior of the outlet 106.

Also coupled to the support plate(s) 704 can be a finish cap 706.Similar to the construction of the cap portions 702, the finish cap 706can include one or more portions configured to extend at least partiallyaround the outlet 106 and there be coupled or otherwise attached toanother portion of the finish cap 706, and so on until the finish cap706 extends completely around the outlet 106. In at least oneembodiment, the finish cap 706 can include two half-circle finish cap706 portions that interconnect halfway around the outlet 106, therebyproviding a full circular finish cap 706. In other embodiments, thefinish cap 706 can include a single portion that extends completelyaround the circumference of the outlet 106.

In an exemplary embodiment, the finish cap 706 can also be coupled to aseries of finish support plates 708 (only one shown), which can becoupled to or otherwise attached to the vessel casing 108. In one ormore embodiments, the finish support plates 708 can becircumferentially-disposed around the vessel casing 108 and eitherwelded or mechanically or otherwise attached thereto. In at least oneembodiment, there can be about sixteen finish support plates 708circumferentially-disposed around the exterior of the vessel casing 108and configured to provide support to the finish cap 706.

Referring to FIG. 8, illustrated is a magnified view of a section of thecap portions 702 as indicated in FIG. 7. In an exemplary embodiment,each cap portion 702 can be supported by rigid straps 710 coupled at anend distal to the outlet 106, and also supported by rigid straps 711coupled at an end proximal to the outlet 106. As illustrated, the rigidstraps 710, 711 can be bent or otherwise shaped to be coupled to thebottom of one cap portion 702 and to the top of the subsequent capportion 702, in a generally descending direction. At least one rigidstrap 710 can be coupled to the bottom of the bottom-most cap portion702 and also to the top of the finish cap 706 (not shown).

In an exemplary embodiment, the rigid straps 710, 711 can include a thinstrip of rigid material, such as a strip of stainless steel or aluminum,but can also include a strip of other rigid materials, such as plasticsor other metals. In at least one embodiment, the rigid straps 710, 711can be about one inch in width, but other exemplary embodiments caninclude rigid straps 710, 711 of varying widths to suit a particularapplication. In one or more embodiments, a plurality of the rigid straps710, 711 can be spaced equidistantly around the outlet 106, therebyproviding support to the several cap portions 702. In at least oneembodiment, the rigid straps 710, 711 can be spaced on about six inchcenters at the periphery of the cap portions 702 around the outlet 106.As illustrated, the rigid straps 710, 711 can be coupled to the capportions 702 and finish cap 706 by mechanical means, such asself-tapping screws 712. One of skill in the art would, however,appreciate that the rigid straps 710, 711 may be coupled by anyavailable means without departing from the scope of the invention.

In an exemplary embodiment, portions of a screen material 714 can alsobe disposed around the outlet 106 to prevent the influx of animal life,such as birds and other foreign matter, into the exterior of the tophead 107 where the concave casing 302 is located. In at least oneembodiment, the screen material 714 can be a wire mesh, but can also bemade of other materials, such as plastics. As illustrated, the screenmaterial 714 can be interposed between the cap portions 702 and therigid straps 711, and coupled or attached thereto by a coupling means,such as the self-tapping screws 712. As shown in FIG. 7, the screenmaterial 714 can also be used in conjunction with the interconnection ofthe finish cap 706 and the finish support plated 708, thereby providinga barrier configured to prevent the influx of animals and other foreignmatter up through the bottom of the finish cap 706.

At least some of the cap portions 702 can include a lip section 716configured to prevent the influx of rain into the exterior of the tophead 107. For example, the lip sections 716 can be configured to stopblowing rain, which may enter at a substantially 90° angle with respectto horizontal. The remaining portion of the cap portions 702 can begenerally disposed at a decline with respect to horizontal, therebyallowing any accumulated precipitation to drain from the rain shield700.

In an exemplary embodiment, the rain shield 700 can also provide aheat-dissipative effect for the cyclone vessel 102. In exemplaryoperation, heat rising from the cyclone vessel 102 in the direction ofarrow A (FIG. 8) can be emitted via the open spaces betweenvertically-adjacent cap portions 702 in the direction of arrows B bymeans of convection. To accomplish this in a more efficient manner, thecap portions 702 can be vertically-offset from each other byprogressively smaller distances corresponding to the vertical point ofthe outlet 106. In other words, the higher the vertical position on theoutlet 106, the smaller the outlet between adjacent cap portions 702. Ascan be appreciated, progressively smaller outlet paths can force moreheat out the lower and larger outlet paths by means of convective aircurrents, thereby allowing a greater amount of heat to escape withlittle or no restriction.

Embodiments of the present disclosure further relate to any one or moreof the following paragraphs:

1. A rain shield for a cyclone, comprising: one or more cap portionscircumferentially-disposed around an outlet of the cyclone and having anend distal to the outlet and an end proximal to the outlet; a series ofsupport plates coupled to the one or more cap portions and also coupledto the outlet; a finish cap circumferentially-disposed around the outletof the pressure cyclone, the finish cap being coupled to the series ofsupport plates and also coupled to a series of finish support plates,wherein the finish support plates are coupled to a vessel casing of thepressure cyclone; a first plurality of rigid straps coupled to the oneor more cap portions at the end distal to the outlet; a second pluralityof rigid straps coupled to the one or more cap portions at the endproximal to the outlet; and a screen material coupled to the one or morecap portions at the end proximal the outlet and also coupled to thesecond plurality of rigid straps.

2. The rain shield of paragraph 1, wherein the one or more cap portionsfurther comprises a lip section disposed at the end proximal the outletfor preventing an influx of rain.

3. The rain shield of paragraphs 1 or 2, wherein the one or more capportions comprises two or more cap portions offset from each other alonga length of the outlet.

4. The rain shield according to any one of paragraphs 1-3, wherein thefirst plurality of rigid straps are coupled to two or more cap portionsat the end distal to the outlet and configured to support and joinadjacent cap portions and the second plurality of rigid straps arecoupled to two or more cap portions at the end proximal to the outletand configured to support and join the adjacent cap portions.

5. The rain shield according to any one of paragraphs 1-4, wherein theone or more cap portions dissipate heat from the pressure cyclone viaopen spaces defined between the adjacent cap portions.

6. The rain shield of paragraph 4, wherein the one or more cap portionscomprises at least three cap portions, and wherein the adjacent capportions are offset from each other by a progressively smaller distancecorresponding to the length along the outlet.

7. The rain shield according to any one of paragraphs 1-6, wherein theone or more cap portions are disposed at a decline with respect tohorizontal to drain precipitation away from the pressure cyclone.

8. The rain shield according to any one of paragraphs 1-7, wherein thecyclone comprises a concave top head.

9. The rain shield of paragraph 8, wherein the concave top headcomprises a substantially flat roof disposed in an interior of thecyclone.

10. The rain shield according to any one of paragraphs 1-9, wherein thecyclone comprises: a cyclone vessel having an inlet coupled thereto, theinlet configured to receive a particulate-fluid suspension comprising afluid and at least one solid particulate suspended therein, and whereinthe outlet of the cyclone is configured to remove the fluid separatedfrom the particulate-fluid suspension separated fluids from the cyclonevessel; and a concave top head coupled to the cyclone vessel andcircumferentially-disposed about the outlet tube, the concave top headcomprising a substantially flat cyclone roof disposed in an interior ofthe cyclone vessel.

11. The rain shield of paragraph 10, wherein the cyclone furthercomprises an inlet nozzle disposed within the inlet and having a firstsurface and a second surface, and wherein the first surface transitionsto an inner cylindrical surface of the interior of the cyclone vesseland the second surface transitions to the substantially flat cycloneroof.

12. A rain shield, comprising: two or more cap portionscircumferentially-disposed around an outlet of a cyclone having aconcave top head and having an end distal to the outlet and an endproximal to the outlet, wherein the two or more cap portions aredisposed at a decline with respect to horizontal and are offset fromeach other along a length of the outlet; a series of support platescoupled to the one or more cap portions and also coupled to the outlet;a finish cap circumferentially-disposed around the outlet of thepressure cyclone, the finish cap being coupled to the series of supportplates and also coupled to a series of finish support plates, whereinthe finish support plates are coupled to a vessel casing of the pressurecyclone; a first plurality of rigid straps coupled to the two or morecap portions at the end distal to the outlet and configured to supportand join adjacent cap portions; a second plurality of rigid strapscoupled to the two or more cap portions at the end proximal to theoutlet and configured to support and join the adjacent cap portions; anda screen material coupled to the two or more cap portions at the endproximal the outlet and also coupled to the second plurality of rigidstraps.

13. The rain shield of paragraph 12, wherein the two or more capportions further comprises a lip section disposed at the end proximalthe outlet.

14. The rain shield of paragraphs 12 or 13, wherein the concave top headcomprises a substantially flat roof disposed in an interior of thepressure cyclone.

15. A method of separating solid particulates from a particulate-fluidsuspension, comprising: introducing the particulate-fluid suspensioninto a cyclone vessel via an inlet coupled thereto, and wherein thecyclone vessel comprises a roof and a top head having a rain shielddisposed thereon, the rain shield comprising: one or more cap portionscircumferentially-disposed around an outlet of the cyclone and having anend distal to the outlet and an end proximal to the outlet; a series ofsupport plates coupled to the one or more cap portions and also coupledto the outlet; a finish cap circumferentially-disposed around the outletof the pressure cyclone, the finish cap being coupled to the series ofsupport plates and also coupled to a series of finish support plates,wherein the finish support plates are coupled to a vessel casing of thepressure cyclone; a first plurality of rigid straps coupled to the oneor more cap portions at the end distal to the outlet; a second pluralityof rigid straps coupled to the one or more cap portions at the endproximal to the outlet; and a screen material coupled to the one or morecap portions at the end proximal the outlet and also coupled to thesecond plurality of rigid straps; creating a vortex within the cyclonevessel to drive the solid particulates toward the inner cylindricalsurface and produce a reduced particulate loading particulate-fluidsuspension; and removing the reduced particulate loadingparticulate-fluid suspension from the cyclone vessel through the outlet.

16. The method of paragraph 15, further comprising operating the cyclonevessel at pressures ranging from about 50 psi to about 800 psi.

17. The method of paragraphs 15 or 16,wherein the inlet comprises arectangular inlet nozzle having a first surface tangent to an innercylindrical surface of the cyclone vessel and a second surfacesubstantially parallel to and continuous with a cyclone roof of aconcave top head.

18. The method of paragraph 17, further comprising: disposing an inletcasing around a length of the inlet nozzle; transitioning the inletcasing from a circular cross-section at a first end of the inlet casingto an elliptical cross-section at a second end of the inlet casing alongthe length of the inlet nozzle; and coupling the second end of inletcasing having the elliptical cross-section to the cyclone vessel.

19. The method according to any one of paragraphs 15-18, wherein thecyclone roof is substantially flat.

20. The method of paragraph 19, wherein the cyclone roof comprises aseries of pie-shaped refractory bricks configured tocircumferentially-surround the outlet tube.

Certain embodiments and features have been described using a set ofnumerical upper limits and a set of numerical lower limits. It should beappreciated that ranges from any lower limit to any upper limit arecontemplated unless otherwise indicated. Certain lower limits, upperlimits and ranges appear in one or more claims below. All numericalvalues are “about” or “approximately” the indicated value, and take intoaccount experimental error and variations that would be expected by aperson having ordinary skill in the art.

Various terms have been defined above. To the extent a term used in aclaim is not defined above, it should be given the broadest definitionpersons in the pertinent art have given that term as reflected in atleast one printed publication or issued patent. Furthermore, allpatents, test procedures, and other documents cited in this applicationare fully incorporated by reference to the extent such disclosure is notinconsistent with this application and for all jurisdictions in whichsuch incorporation is permitted.

While the foregoing is directed to embodiments of the present invention,other and further embodiments of the invention may be devised withoutdeparting from the basic scope thereof, and the scope thereof isdetermined by the claims that follow.

1. A rain shield for a cyclone, comprising: at least a first sloped trayand a second sloped tray vertically disposed with respect to one anotherabout a longitudinal axis, each tray having an aperture formedtherethrough; at least one support member coupled to at least one of thefirst and second trays and extending toward the longitudinal axis; atleast one support body coupled to at least one of the first and secondtrays and extending toward the longitudinal axis; a first plurality ofstraps coupled to an outer edge of the first and second trays; a secondplurality of straps coupled to an inner edge of the first and secondtrays; and a screen at least partially disposed between the first andsecond trays.
 2. The rain shield of claim 1, wherein at least one of thefirst and second trays comprises a plurality of segments that togetherform the at least one of the first and second sloped trays.
 3. The rainshield of claim 1, wherein the first and second trays each have afrusto-conical shape, and wherein each aperture of each tray is axiallyaligned with one another about the longitudinal axis.
 4. The rain shieldof claim 1, wherein an outlet of a cyclone is disposed through theapertures of the first and second trays such that the first and secondtrays are circumferentially-disposed about the outlet of the cyclone. 5.The rain shield of claim 4, wherein the cyclone comprises a concave tophead.
 6. The rain shield of claim 1, wherein the first and second traysare offset from each other along the longitudinal axis.
 7. The rainshield of claim 1, wherein the first plurality of straps and the secondplurality of straps are configured to support and join the first andsecond trays in fixed positions relative to one another.
 8. The rainshield of claim 7, wherein an outlet of a cyclone is disposed throughthe apertures of the first and second trays such that the first andsecond trays are circumferentially-disposed about the outlet of thecyclone, and wherein the first and second trays dissipate heat from thecyclone via one or more open spaces defined between the first and secondtrays.
 9. The rain shield of claim 7, further comprising at least threesloped trays, wherein the adjacent trays are offset from each other by aprogressively smaller distance corresponding to a length along thelongitudinal axis.
 10. The rain shield of claim 1, wherein an outlet ofa cyclone is disposed through the apertures of the first and secondtrays such that the first and second trays arecircumferentially-disposed about the outlet of the cyclone, and whereinthe slope of the first and second sloped trays allows precipitation todrain away from the cyclone.
 11. The rain shield of claim 1, whereineach of the first and second trays further comprises a lip disposedabout the outer edge.
 12. A rain shield for a cyclone, comprising: atleast a first sloped tray and a second sloped tray vertically disposedwith respect to one another about a longitudinal axis, each traycircumferentially-disposed around an outlet of a cyclone having aconcave top head; at least one support member coupled to at least one ofthe first and second trays and in contact with the outlet; at least onesupport body coupled to at least one of the first and second trays andin contact with a vessel casing of the cyclone; a first plurality ofstraps coupled to an outer edge of the first and second trays; a secondplurality of straps coupled to an inner edge of the first and secondtrays; and a screen at least partially disposed between the first andsecond trays.
 13. The rain shield of claim 12, wherein each of the firstand second trays further comprises a lip disposed about the outer edge.14. The rain shield of claim 12, wherein the concave top head comprisesa substantially flat roof disposed in an interior of the cyclone.
 15. Amethod of separating solid particulates from a particulate-fluidsuspension, comprising: introducing the particulate-fluid suspensioninto a cyclone via an inlet coupled thereto, wherein the cyclonecomprises a roof and a top head having a rain shield disposed thereon,the rain shield comprising: at least a first sloped tray and a secondsloped tray vertically disposed with respect to one another about alongitudinal axis, each tray having an aperture formed therethrough; atleast one support member coupled to at least one of the first and secondtrays and extending toward the longitudinal axis; at least one supportbody coupled to at least one of the first and second trays and extendingtoward the longitudinal axis; a first plurality of straps coupled to anouter edge of the first and second trays; a second plurality of strapscoupled to an inner edge of the first and second trays; and a screen atleast partially disposed between the first and second trays; forming avortex within the cyclone to drive the solid particulates toward aninner cylindrical surface and produce a reduced particulate loadingparticulate-fluid suspension; and removing the reduced particulateloading particulate-fluid suspension from the cyclone through theoutlet.
 16. The method of claim 15, further comprising operating thecyclone at a temperature of about 800° C. to about 1,000° C. anddissipating heat from the cyclone through the rain shield and away fromthe cyclone.
 17. The method of claim 15, wherein the inlet comprises arectangular inlet nozzle having a first surface tangent to an innercylindrical surface of the cyclone and a second surface substantiallyparallel to and continuous with the roof of the cyclone.
 18. The methodof claim 17, further comprising: disposing an inlet casing around anexternal surface of the inlet nozzle and along a length thereof;transitioning the inlet casing from a circular cross-section at a firstend of the inlet casing to an elliptical cross-section at a second endof the inlet casing along the length of the inlet nozzle; and couplingthe second end of inlet casing having the elliptical cross-section tothe cyclone.
 19. The method of claim 15, wherein the roof of the cycloneis substantially flat.
 20. The method of claim 19, wherein a series ofpie-shaped refractory bricks configured to circumferentially-surroundthe outlet tube are disposed on the roof of the cyclone.